Many parts require high strength materials, exhibiting high temperatures or where formability should be reduced, requiring new processing technologies. The application of hybrid manufacturing processes can answer the needs. This paper gives first a classification of hybrid manufacturing processes, followed by a description of various productivity improvements. The latter is also demonstrated by various examples in cutting, grinding, forming and chemical & physical processes like EDM, ECM and laser.
Materializing Continuum Damage Mechanics (CDM), numerical modeling of discrete internal cracks, namely central bursts, in direct forward extrusion process is presented. Accordingly, in a thermodynamically consistent setting, a local Lemaitre variant damage model with quasi‐unilateral evolution is coupled with hyperelastic‐plasticity. The formulations are constructed in the principal axes where simultaneous and staggered local integration schemes are efficiently developed. To this end, the framework is implemented as ABAQUS/VUMAT subroutine to be used in an explicit FE solution scheme and used in direct forward extrusion simulations for bearing steel 100Cr6. On the numerical side, the performance of the staggered schemes is compared with that of the simultaneous scheme. On the physical side, the relative predictive qualities are observed. Besides, the investigations reveal that, in application of the quasi‐unilateral conditions, the crack closure parameter has an indispensable effect on the damage accumulation zones by determining their internal or superficial character. Combining a suitably selected crack closure parameter with the element deletion procedure, discrete cracks are obtained. The periodicity of the cracks shows
well accordance with the experimental facts.
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